Looking for the perfect martial arts accessory that fits your hands and budget? Look no further, the Brass Knuckles are the ultimate answer. This hand-held ninja weapon is extremely easy to customize and embellish. However, if you wish to design your own knuckle buckle, just follow a few easy steps.
Brass knuckles are usually made of titanium and brass due to the durability and sturdiness of these metals. You can also construct knuckles from wood if the necessary gear for brass knuckles construction is not available. Get the right tools and follow the instructions rigidly. Ensure your safety at all times during this process.
Designing the Brass Knuckles
Designing is an extremely important step for perfect construction. One can utilize boundless creativity in this step and integrate several styles into one product.
Get a Reference Image
A reference image will help you put your abstract thoughts into a solid idea. Any search engine can yield thousands of results for your interests. Shortlist the desired pictures. A better idea would be to create a mood board on Pinterest and then select specifications. Your reference image should be a stencil drawing highlighting the measurements and curves of the brass knuckle. The front side portrayal is necessary for accurate cuts. Don’t select an image with a distracting background or intricate trademarks.
If you trust your memory and instinct then there is no need for an outline or a reference picture. However, this is only suggested for professionals. If you are a novice with absolutely no experience, a reference image is a good contingency measure for you. Need design inspiration? SwordsSwords has hundreds of innovative brass knuckles to satisfy your curiosity.
Sketch the Design
While printing out the outline is an easier option, many experts recommend sketching. Put pencil to paper and let your hand trace the image in your mind. This helps in familiarizing the muscle memory with the design of the brass knuckles. It also gives an idea of how the cuts and curves need to be made. The rough measurements put the hand size and grip size in perspective. During this step, you can easily evaluate your abilities and skills for brass knuckle construction.
The standardized measurements for an average adult are as follows. There must be a distance of 1.18-1.38 inches or 30-35 mm between the bottom of the handle and the bottom of the hole meant for the middle finger. This hole usually resides above the others. Additionally, there should be at least 0.98-1.06 inches or 25-27mm diameter for each finger. Make the gaps egg-shaped rather than perfectly round. This will give perfect breathing room to all the digits.
Cutting and Tracing
Cut out the paper diagram carefully after perfecting the measurements and design. The next step is tracing the design on your desired metal. Use duct tape to secure the design on the surface and trace it with a permanent marker. The ink will leave outlines. Enhance this outline with a pencil and darken it. Then, you can set the paper drawing aside. Ideally, the metal sheet or block you use should be 7-12mm in thickness. Both brass and aluminum work well in knuckle duster construction.
Cutting the Metal
Safety First
Personal safety must be your utmost goal during any construction project. Safety goggles and handyman gloves are essential gear for this project.
Drilling
Use a standing drill or a handheld drill to make rough cuts and separate the unnecessary metal. Follow the marker outline with your drill. A 3.2 mm drilling needle will be sufficient for your project. Drill along with the design pattern. Make a hole along the perimeters of finger holdings.
Punching
This is where the fun begins. Use a screwdriver head or a small hammer to punch out the metal from the holes you made. Keep on striking until the excess metal falls away.
Take the Knuckles Out
Use your fingers to pry out the knuckle duster from the metal block. The finger holes are excellent areas for leverage. This step gives us the perfectly defined brass knuckles in your desired shape. Don’t be discouraged by the roughness, there’s still work left. Make sure to handle the knuckle duster with care.
Finishing the Brass Knuckles
Finishing is the most optimal step to eliminate any design errors and add in the customization for your brass knuckles.
Smoothing down
The edges must be smoothed out. You can do this by using a rotary tool fitted with the soft metal implement. Use this equipment over all the deep groves and pointy edges. Keep smoothing till you can’t feel any sharp edges or points. Keep your gloves on and hold the knuckle duster in a firm grip. Slipping while smoothing can cause the weaker joints of knuckle duster to fall apart.
Filing the Details
The metal files are perfect to make small details and embellishments on the edges of the brass knuckles. Give them an angle or carve out beautiful patters. The sky is the limit. The metal files can also be used to smooth down the entire brass knuckle in the absence of a rotary tool. However, this might be quite a time consuming and arduous task for novices.
Sanding
Sand the trims and corners with sandpaper. Grind them properly to remove residual metallic impurities. This can be done either by hand or by using an automated sanding belt. Start with larger-grit sandpaper and gradually move towards the finish with a finer-grit 320-400 sandpaper.
Buffing
Buffing makes the brass knuckles safe for everyday usage. Steel wool is the perfect buffer for metallic objects. Therefore, it is most optimal for this project as well. Buff your brass knuckles with steel wool pad in soft and smooth circular motions. Treat the entire knuckle with gentle buffing and don’t ignore any corner or crevice.
Polish the Knuckles
Applying polish is the last step in finishing the brass knuckles. Use a trusted metal polish brand. Make sure to wipe down the duster with a cleaner before polishing. Then, apply metal polish thoroughly into the entire metallic surface. Keep on polishing until all the moisture has evaporated.
Try the Brass Knuckles On
Your brass knuckles are complete! Try them on and judge their fit and comfort. You might observe some design or construction flaws. However, that is quite common for a first-time project. The brass knuckles are perfectly ready for everyday usage and self-protection. Defend yourself proudly with your own creation!
